EP3180467B1 - Hybrid woven textile for composite reinforcement - Google Patents

Hybrid woven textile for composite reinforcement Download PDF

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Publication number
EP3180467B1
EP3180467B1 EP15750905.0A EP15750905A EP3180467B1 EP 3180467 B1 EP3180467 B1 EP 3180467B1 EP 15750905 A EP15750905 A EP 15750905A EP 3180467 B1 EP3180467 B1 EP 3180467B1
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EP
European Patent Office
Prior art keywords
fibers
woven fabric
fabric according
nonwoven
strips
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Active
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EP15750905.0A
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German (de)
English (en)
French (fr)
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EP3180467A1 (en
Inventor
Robert Blackburn
Samuel Jestyn Hill
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Cytec Industries Inc
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Cytec Industries Inc
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    • D—TEXTILES; PAPER
    • D03—WEAVING
    • D03D—WOVEN FABRICS; METHODS OF WEAVING; LOOMS
    • D03D13/00—Woven fabrics characterised by the special disposition of the warp or weft threads, e.g. with curved weft threads, with discontinuous warp threads, with diagonal warp or weft
    • D—TEXTILES; PAPER
    • D03—WEAVING
    • D03D—WOVEN FABRICS; METHODS OF WEAVING; LOOMS
    • D03D15/00—Woven fabrics characterised by the material, structure or properties of the fibres, filaments, yarns, threads or other warp or weft elements used
    • D03D15/40—Woven fabrics characterised by the material, structure or properties of the fibres, filaments, yarns, threads or other warp or weft elements used characterised by the structure of the yarns or threads
    • D03D15/44—Woven fabrics characterised by the material, structure or properties of the fibres, filaments, yarns, threads or other warp or weft elements used characterised by the structure of the yarns or threads with specific cross-section or surface shape
    • D03D15/46—Flat yarns, e.g. tapes or films
    • D—TEXTILES; PAPER
    • D03—WEAVING
    • D03D—WOVEN FABRICS; METHODS OF WEAVING; LOOMS
    • D03D15/00—Woven fabrics characterised by the material, structure or properties of the fibres, filaments, yarns, threads or other warp or weft elements used
    • D—TEXTILES; PAPER
    • D03—WEAVING
    • D03D—WOVEN FABRICS; METHODS OF WEAVING; LOOMS
    • D03D15/00—Woven fabrics characterised by the material, structure or properties of the fibres, filaments, yarns, threads or other warp or weft elements used
    • D03D15/20—Woven fabrics characterised by the material, structure or properties of the fibres, filaments, yarns, threads or other warp or weft elements used characterised by the material of the fibres or filaments constituting the yarns or threads
    • D03D15/242—Woven fabrics characterised by the material, structure or properties of the fibres, filaments, yarns, threads or other warp or weft elements used characterised by the material of the fibres or filaments constituting the yarns or threads inorganic, e.g. basalt
    • D03D15/267—Glass
    • D—TEXTILES; PAPER
    • D03—WEAVING
    • D03D—WOVEN FABRICS; METHODS OF WEAVING; LOOMS
    • D03D15/00—Woven fabrics characterised by the material, structure or properties of the fibres, filaments, yarns, threads or other warp or weft elements used
    • D03D15/20—Woven fabrics characterised by the material, structure or properties of the fibres, filaments, yarns, threads or other warp or weft elements used characterised by the material of the fibres or filaments constituting the yarns or threads
    • D03D15/242—Woven fabrics characterised by the material, structure or properties of the fibres, filaments, yarns, threads or other warp or weft elements used characterised by the material of the fibres or filaments constituting the yarns or threads inorganic, e.g. basalt
    • D03D15/275—Carbon fibres
    • D—TEXTILES; PAPER
    • D03—WEAVING
    • D03D—WOVEN FABRICS; METHODS OF WEAVING; LOOMS
    • D03D15/00—Woven fabrics characterised by the material, structure or properties of the fibres, filaments, yarns, threads or other warp or weft elements used
    • D03D15/50—Woven fabrics characterised by the material, structure or properties of the fibres, filaments, yarns, threads or other warp or weft elements used characterised by the properties of the yarns or threads
    • D03D15/573—Tensile strength
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29B—PREPARATION OR PRETREATMENT OF THE MATERIAL TO BE SHAPED; MAKING GRANULES OR PREFORMS; RECOVERY OF PLASTICS OR OTHER CONSTITUENTS OF WASTE MATERIAL CONTAINING PLASTICS
    • B29B11/00—Making preforms
    • B29B11/14—Making preforms characterised by structure or composition
    • B29B11/16—Making preforms characterised by structure or composition comprising fillers or reinforcement
    • D—TEXTILES; PAPER
    • D10—INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
    • D10B—INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
    • D10B2101/00—Inorganic fibres
    • D10B2101/10—Inorganic fibres based on non-oxides other than metals
    • D10B2101/12—Carbon; Pitch
    • D—TEXTILES; PAPER
    • D10—INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
    • D10B—INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
    • D10B2331/00—Fibres made from polymers obtained otherwise than by reactions only involving carbon-to-carbon unsaturated bonds, e.g. polycondensation products
    • D10B2331/02—Fibres made from polymers obtained otherwise than by reactions only involving carbon-to-carbon unsaturated bonds, e.g. polycondensation products polyamides
    • D10B2331/021—Fibres made from polymers obtained otherwise than by reactions only involving carbon-to-carbon unsaturated bonds, e.g. polycondensation products polyamides aromatic polyamides, e.g. aramides
    • D—TEXTILES; PAPER
    • D10—INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
    • D10B—INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
    • D10B2505/00—Industrial
    • D10B2505/02—Reinforcing materials; Prepregs

Definitions

  • Three-dimensional polymer composite parts can be manufactured using different methods, one of which is autoclave molding.
  • autoclave molding method a fabric, usually composed of carbon fibers, is pre-impregnated with a resin matrix. Prepregs are typically laid in a mold and then heated under vacuum to cure the impregnated resin and create the final composite part.
  • the prepregs to be molded into a composite have the advantage of ease of use and high reliability. However, they also have the disadvantage of having limited drapability (i.e. ability to drape).
  • RTM Resin Transfer Molding
  • VARTM Vacuum-assisted Resin Transfer Molding
  • layers of dry reinforcement fibers (without matrix resin) is shaped and compacted into a cohesive, shaped structure called a "preform".
  • This preform is then infused with an uncured liquid resin, often in a closed mold or enclosed vacuum bag. After the resin infusion stage is completed, the resin is cured resulting in a solid composite part.
  • Liquid molding technology is especially useful in the manufacturing complex-shaped structures which are otherwise difficult to manufacture using conventional prepreg technologies.
  • dry, flexible fibrous materials used for forming preforms can have significant advantages over standard, resin-impregnated prepreg materials due their longer shelf life and applicability to more complex geometries.
  • a woven fabric according to the preamble of claim 1 is known from US2012/0237707A1 .
  • An object of the present disclosure is to provide a hybrid, woven textile material according to claim 1 that can be used in the manufacturing of fiber-reinforced composite materials.
  • the hybrid textile material is a woven fabric composed of unidirectional fibers interlaced with strips of non-woven fibers in a weaving pattern.
  • the hybrid, woven textile material is porous and permeable with respect to liquid resins used in RTM processes and a preform formed from this woven textile material can be infused with liquid resins during RTM processes.
  • Some available techniques of manufacturing textiles based on unidirectional fibers include: weaving, stitching or bonding.
  • Woven unidirectional configuration also referred to as a Uni-Weave
  • ancillary yarns can be woven in the secondary axis in order to anchor the structural fibers in the principal axis. These ancillary yarns are typically fine fibers in order to minimize the fiber crimp.
  • FIGS. 1 and 2 An example of a uni-weave configuration and a crimping model are shown in FIGS. 1 and 2 , respectively.
  • Common ancillary fiber types used in this configuration are glass, polyester and co-polyamides. This type of configuration is more suitable for 0° oriented reinforcement fabric but can also be utilized to construct 90° and polar orientated fabrics.
  • Uni-weave fabrics are typically found to have 95% of the fiber mass in the principal orientation and 5% in the secondary orientation.
  • the characteristics found of this type of fabrics are good permeability and drapability (i.e., ability to drape) at the cost of poor textile integrity and low in-plane mechanical properties.
  • Typically 0° tensile and compressive properties are observed to suffer from the crimping effects induced by the weft ancillary fibers. Adjusting the weave pattern of the fabric can help reduce the frequency of the crimping effects yet this typically comes with further reduction to the textile stability.
  • Stitched unidirectional configuration also referred to as a Uni-Stitch
  • a Uni-Stitch is based on the use of warp-knitting machines to anchor the structural fibers to the principal axis through the use of a through thickness stich that interlocks with a floating weft ancillary yarn and thus constrains the principal fibers between the stitching thread and ancillary yarn.
  • An example of a uni-stitch configuration and stitch anchoring mechanism are illustrated in FIGS. 3 and 4 , respectively.
  • the stitching threads used in this method are typically either polyester or copolyamide while the ancillary threads are either the same or made of glass, the mass of stitching thread and ancillary yarn in these configurations is typically found to be 2%-6% of the total mass.
  • This type of unidirectional textile is suitable as 0° oriented reinforcement fabric, however, 90° oriented reinforcement may be possible.
  • the uni-stitch configurations typically show an improvement in mechanical performance over woven structures due to a relatively reduced level of out-of-plane crimp but still show reductions when compared to prepreg tape product due to the inter-tow gaps and residual crimp from the stitching. Consequently, the permeability of these fabrics is usually found to be higher than those of their woven equivalents while the handling stability is also improved due to the localized anchoring efficiency of the stitching threads.
  • Another fabric configuration is that produced by bonding or laminating the unidirectional fibers in place with a polymeric material.
  • Some binding approaches include the use of epoxy binding agents, thermoplastic veils and polymeric yarns.
  • This approach for producing a dry unidirectional architecture undoubtedly provides the closest mechanical performance to that of pre-impregnated tape due to the high levels of fiber alignment and near zero inter-tow gaps that can be achieved.
  • This very high level of fiber nesting though has a significant reduction on the permeability of these fabric configurations where the through-thickness permeability is several orders of magnitude lower than that of the alternative styles. This makes the use of this textile configuration more suitable to narrow unidirectional tapes where permeability tailoring can be achieved within the preform construction.
  • FIG. 5 depicts an exemplary hybrid woven fabric having unidirectional fibers in the form of continuous fiber tows 10 interlaced with nonwoven strips 11.
  • FIG. 6 is a cross-sectional view of the woven fabric shown in FIG. 5 .
  • the unidirectional fiber tows 10 are arranged parallel to each other in a sheet-like formation and extending in a first direction, e.g. the warp direction, and the nonwoven strips 11 are extending in a second direction, e.g. the weft direction, transverse to the first direction.
  • Each nonwoven strip floats over multiple tows and then under multiple tows in a weaving pattern.
  • Each fiber tow 10 is a bundle of multiple fiber filaments.
  • the nonwoven strips 11 are formed from a lightweight, nonwoven veil composed of randomly arranged and/or randomly oriented fibers. It is preferred that the nonwoven fibrous veil is a lightweight material with an areal weight of 1 gsm (g/m 2 ) to 40 gsm, more preferably 3 gsm to 10 gsm. Each nonwoven strip is flexible and has a narrow width relative to its length. In one embodiment, the width of the non-woven strip is from 5 mm to 40 mm, preferably 10 mm to 30 mm, and the thickness is from 10 ⁇ m to 60 ⁇ m (0.01-0.05 mm).
  • the weaving pattern may be of any conventional weaving structure such as plain weave (shown in FIG. 5 ), satin weave, or twill weave.
  • the unidirectional fibers are in the form of continuous fiber tows.
  • Each fiber tow is composed of hundreds of smaller continuous fiber filaments.
  • the fiber tows may have 1000 to 100,000 fiber filaments per tow, and in some embodiments, 3000 to 24000 filaments per tow.
  • the fiber filaments may have cross-sectional diameters within the range of 3-15 ⁇ m, preferably 4-7 ⁇ m.
  • Suitable fibers are those used as structural reinforcement of high-performance composites, such as composite parts for aerospace and automotive applications.
  • the structural fibers may be made from high-strength materials such as carbon (including graphite), glass (including E-glass or S-glass fibers), quartz, alumina, zirconia, silicon carbide, and other ceramics, and tough polymers such as aramids (including Kevlar), high-modulus polyethylene (PE), polyester, poly-p-phenylene-benzobisoxazole (PBO), and hybrid combinations thereof.
  • high-strength composite structures such as primary parts of an airplane, the unidirectional fibers preferably have a tensile strength of greater than 500 ksi.
  • the unidirectional fibers are carbon fibers.
  • the unidirectional fibers may be coated with sizing compositions and/or finishes that serve multiple purposes, including facilitating handling, protection of the fibers from compaction and process induced damage, aiding in compatibility and wetting of the fibers by the resin, and overall enhancement of the composites performance.
  • the nonwoven strips described above may be formed by slitting a larger nonwoven veil and the slit nonwoven material is then used for weaving.
  • the nonwoven veil is composed of intermingled, randomly arranged fibers and a small amount of polymeric binder for holding the fibers together. It is desirable to provide a nonwoven veil having a sufficient amount of binder to hold the fibers together and but the binder amount is small enough to leave the resulting veil porous and permeable to liquid and air, particularly liquid resin.
  • Suitable polymeric binders include poly vinyl alcohol (PVA), polyester, co-polyester, crosslinked polyester, styrene acrylic, phenoxy and polyurethane, combinations and copolymers thereof.
  • the amount of binder is 5% to 25% by weight, based on the total weight of the veil.
  • the nonwoven veil is flexible and is self-supporting, meaning that it does not require a supporting carrier.
  • the nonwoven veil is a single-layer material, which is not attached to another layer of fibers.
  • the fibers of the nonwoven veil may be chopped or continuous fiber filaments or combination thereof.
  • the nonwoven fiber materials for the nonwoven veil may be selected from carbon, glass, metals, quartz, polymers and copolymers thereof, hybrids thereof (e.g. carbon/glass hybrid), and combinations thereof.
  • Polymeric materials for the fibers may be selected from: aramid; polyester; polyamides, including aliphatic polyamides, cycloaliphatic polyamides, and aromatic polyamides; polyphthalamide; polyamide-imide; polyarylsufones, including polyethersulfone and polyetherethersulfones; polysulfones; polyphenylene sulfone; polyaryletherketones, including polyetheretherketone and polyetherketoneketone; polyphenylene sulfide; elastomeric polyamides; polyphenylene ether; polyurethane; liquid crystal polymers (LCP); phenoxy; polyacrylonitrile, acrylate polymers, and copolymers thereof.
  • the fibers of the veil may also be metal coated.
  • the nonwoven strips are composed of carbon fibers.
  • the majority of the nonwoven fibers have cross-section diameters in the range of about 1 ⁇ m to 40 ⁇ m, with the major portion of the fibers being more preferably in the range of about 4 ⁇ m to 20 ⁇ m in diameter.
  • the woven fabric (based on the combination of unidirectional fiber tows and nonwoven strips) has an areal weight of 50 gsm to 400 gsm, preferably, 100 gsm to 200 gsm.
  • the benefit of the hybrid textile material described herein includes: extremely low crimp of the structural fibers due to the low thickness of the nonwoven veil; improved permeability due to the porous structure of the nonwoven strips; improved fracture behavior from the nonwoven strips reinforcing the interlaminar zone of the preform or final composite laminate; improved lay-up efficiency during the preparation of the preform from having off-axis fibers in a continuous textile format; potentially improved handling behavior if the non-woven were to contain a stabilizing binder and the textile laminated.
  • the woven fabric disclosed herein could be produced in varying configurations so as to provide 0°, 90°, + ⁇ ° or - ⁇ ° fiber orientation.
  • the nonwoven veil discussed above may be produced by a conventional wet-laid process, as an example.
  • wet chopped fibers are dispersed in a water slurry that contains binder(s), surfactant(s), viscosity modifier(s), defoaming agent(s), and/or other chemical agents.
  • the slurry is intensely agitated so that the fibers become dispersed.
  • the slurry containing the fibers is deposited onto a moving screen where a substantial portion of the water is removed to form a web.
  • the resulting mat is dried to remove any remaining water and to cure the binder(s).
  • the formed non-woven mat/veil is an assembly of dispersed, individual fiber filaments arranged in random orientation. Wet-laid processes are typically used when a uniform distribution of fibers and/or weight is desired.
  • the final nonwoven veil contains at least about 90 wt. % fibers (excluding sizing/binder chemicals), on a dry basis, e.g. about 93 wt. % to about 99 wt. % fibers, on a dry basis, excluding the sizing/binder.
  • An additional binder may be applied to the nonwoven veil after it is made but before weaving to improve the veil's stability and to aid preform compaction during the manufacturing of composite parts.
  • Suitable binders for the stabilization of the nonwoven veil include epoxy resins, thermoplastic polymers or a combination thereof.
  • a particularly suitable binder for the stabilization of the nonwoven veil is the polyarylether thermoplast-epoxy binder disclosed in U.S. Patent Nc 8,927,662 .
  • This binder may be applied in powder form to the veil using a conventional coating technique such as dry-bar coating, whereby dry powder is coated onto a release paper using a roll-over-roll or knife-over-roll coater, and the powder is then transferred on the veil.
  • liquid binder composition described in U.S. Pub. Nc 2014/0179187 .
  • Liquid binders disclosed in U.S. Patent Application No. 14/750,327, filed on 25 June 2015 are also suitable.
  • the liquid binder may be applied to the veil by dip-coating, as an example.
  • the total amount of binders in the final veil should not exceed 25% by weight.
  • the hybrid woven fabric disclosed herein may be manufactured on a standard rapier loom.
  • the unidirectional (e.g. carbon) fibres are spread offline to the correct width based on the FAW requirement.
  • the non-woven is manufactured in a wide form in the process detailed above and slit down to the required width.
  • the spread fibers and non-woven strips are spooled on individual cassettes and mounted onto the loom shaft. Multiple fiber cassettes are required in the warp direction to achieve the targeted textile width while a single cassette of non-woven strip is required as the weft insertion is done individually during the weaving process.
  • the adjacent fibers are pulled in opposite directions (i.e. up or down) and the weft nonwoven strip is pulled through the shed to create the weave pattern. Once the weft nonwoven strip is positioned, the warp fibers are release and pulled under tension to consolidate the weave.
  • the hybrid woven textile material disclosed herein is particularly suitable for forming preforms to be used in RTM processes because it is porous and permeable with respect to liquid resins used in such RTM process.
  • To form the preform multiple plies of textile material are laid up to a desired thickness.
  • the amount of binder in the preform is preferably less than 15% by weight based on the total weight of the preform.
  • the preform is placed in a closed mold.
  • the mold is heated to a predetermined temperature and a low-viscosity resin is injected into the mold to infuse the preform with the resin.
  • the resin is then cured to form a composite part.
  • the hybrid woven textile material may be used to form prepregs using conventional resin impregnation techniques.
  • FIG. 7 shows a hybrid veil-woven fabric made according to one embodiment of the present disclosure.
  • Unidirectional carbon fiber tows IMS65 from Toho Tenax
  • the carbon tow has a width of 8 mm and the nonwoven carbon strip has a width of 16 mm.
  • the nonwoven carbon strip has an areal weight of 8 gsm and was coated with 5 gsm of Cycom ® 7720 binder in powder form (from Cytec Engineered Materials).
  • the woven fabric has an areal weigh of 110 gsm.
  • Ten (10) plies of the hybrid veil-woven fabric described above were laid up to form a preform.
  • the preform was heated to 130°C under a vacuum bag in a convection oven for 15 minutes and cooled to 25°C under vacuum in order to consolidate the plies.
  • the laminate codes DT, UW, and VW refer to cured composite laminates which were formed with dry tapes, uniweave fabric, and veil-woven fabric, respectively.
  • the other part of the preform was used to measure the in-plane permeability performance.
  • the preform was bagged up without any flow assistance to ensure pure in-plane flow behavior.
  • FIG. 8 The results are illustrated in FIG. 8 . From FIG. 8 , it is evident that the UD tape exhibited a very poor in plane permeability due to the highly aligned fibers restricting resin flow through the preform. In contrast, the woven UD exhibited more crimp resulting in a superior permeability performance. The novel veil-woven configuration exhibited the highest permeability performance due to the inclusion of the nonwoven strips enhancing the flow characteristics within the textile while maintaining the high degree of alignment in the carbon fibers.
  • the RTM method injects the resin in an in-plane direction from one end side of a dry fiber preform toward the other end side. It has been found that the incorporation of nonwoven carbon fibers in a base fabric structure of unidirectional fibers improved permeability and in-plane properties (0° mechanical performance). Significant increase of permeability was found for the preform formed from the hybrid veil-woven fabric (VW) as compared to preforms formed from dry tapes (DT) and uniweave fabric (UW):

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  • Engineering & Computer Science (AREA)
  • Textile Engineering (AREA)
  • Chemical & Material Sciences (AREA)
  • Inorganic Chemistry (AREA)
  • Reinforced Plastic Materials (AREA)
  • Woven Fabrics (AREA)
  • Laminated Bodies (AREA)
  • Nonwoven Fabrics (AREA)
EP15750905.0A 2014-08-13 2015-08-11 Hybrid woven textile for composite reinforcement Active EP3180467B1 (en)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
GBGB1414363.0A GB201414363D0 (en) 2014-08-13 2014-08-13 Hybrid woven textile for composite reinforcement
PCT/US2015/044564 WO2016025427A1 (en) 2014-08-13 2015-08-11 Hybrid woven textile for composite reinforcement

Publications (2)

Publication Number Publication Date
EP3180467A1 EP3180467A1 (en) 2017-06-21
EP3180467B1 true EP3180467B1 (en) 2022-01-19

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Country Status (13)

Country Link
US (1) US10683592B2 (ja)
EP (1) EP3180467B1 (ja)
JP (1) JP6693944B2 (ja)
KR (1) KR102408034B1 (ja)
CN (2) CN106795665A (ja)
AU (1) AU2015301894B2 (ja)
BR (1) BR112017002654B1 (ja)
CA (1) CA2957247C (ja)
ES (1) ES2909962T3 (ja)
GB (1) GB201414363D0 (ja)
RU (1) RU2705997C2 (ja)
TW (1) TW201615911A (ja)
WO (1) WO2016025427A1 (ja)

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JP6693944B2 (ja) 2020-05-13
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CN106795665A (zh) 2017-05-31
TW201615911A (zh) 2016-05-01
ES2909962T3 (es) 2022-05-11
CN112538678A (zh) 2021-03-23
KR20170040350A (ko) 2017-04-12
BR112017002654B1 (pt) 2022-01-04
GB201414363D0 (en) 2014-09-24
US10683592B2 (en) 2020-06-16
JP2017524839A (ja) 2017-08-31
AU2015301894B2 (en) 2020-03-05
CA2957247A1 (en) 2016-02-18
US20160047073A1 (en) 2016-02-18
WO2016025427A1 (en) 2016-02-18
BR112017002654A2 (pt) 2017-12-12
CA2957247C (en) 2022-08-16
EP3180467A1 (en) 2017-06-21
RU2017107468A3 (ja) 2019-03-25
AU2015301894A1 (en) 2017-02-23

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